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Gearboxes

Gearboxes are used in a wide range of industries and are one of the most critical pieces of equipment in almost every manufacturing plant. A defective gearbox can halt a production line, causing costly downtime and raising maintenance costs for emergency repairs. We can choose to rely on a “run-to-failure” maintenance strategy and pay those costs, or we can be proactive and build more life into our critical assets.

 

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Most industrial gearboxes come from the OEM with little more than a fill port, drain port and level plug or dipstick. Sometimes the fill port doubles as an air vent, which is required due to thermal expansion and contraction while others use a spring loaded check valve designed to relieve excess pressure during operations.

While these simple access points are necessary to allow for basic maintenance tasks such as level checks, top-offs or oil changes, they do a poor job of excluding external contamination from entering the oil sump. Did you know that 79% of all gearbox failures are due to lubrication-related issues? To avoid contamination-related breakdowns and thus, costly downtime, a few simple upgrades and modifications can effectively isolate gearboxes from the outside environment, maintaining a completely closed system while promoting lubrication best practices whether the gearbox is running or shut down.

Depending on the size, orientation and type of gearbox, possible modifications include:

• Desiccant breather to exclude airborne particles and moisture
• Quick connects with dust caps on the drain for easy drain/fill and on the fill to add new oil
• 3-D BullsEye® or column sight glass for non-invasive level checks and Oil Sight Glass (BS&W Bowl) for enhanced visual inspections
• Oil sample port to facilitate accurate, repeatable sampling

For large gearboxes, oil life and equipment reliability can be further extended with filtration. Using the same quick connect adapters
used for filling and draining, portable or permanent filtration can be used to remove contaminants.

This gearbox was outfitted with a gearbox adapter kit (including a breather, fill quick connect, and vacuum indicator), a sample valve, and a drain quick connect. Utilizing a filter cart, they were able to see a drastic difference in contamination with just three hours of filtration resulting in a 50-60% increase in gearbox life.

Gearbox Reliability Whitepaper

Most contamination control strategies for gear drives focus too much on the dirt you can see, but the dirt that is the most concerning is actually invisible to the naked eye. The particles that do the most damage are in the 2-5 micron range. This is the range of clearance in many sensitive components including servo valves, bearings and the pitch line of gear teeth. This white paper examines the factors that impact precision lubrication; including lubricant selection, application and contamination control, as well as how to develop precision lubrication practices for enclosed gears.

Modify Your Equipment to Seal and Protect It

Receive a downloadable plan for your specific make and model of equipment. Modification plans include simple addition of hardware such as quick connects, level gauges, breathers and sample ports to facilitate lubrication best practices.



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